Managing Change - MINASF.orgminasf.org/.../2015/04/Grand-Rapids-3.28.15_Managing-Change.pdf ·...
Transcript of Managing Change - MINASF.orgminasf.org/.../2015/04/Grand-Rapids-3.28.15_Managing-Change.pdf ·...
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Managing Change
A Supplier’s Perspective on Qualifying LHE Zinc-Nickel as a
Cadmium Replacement For Aerospace Applications
MINASF, March 28th 2015
Dipsol of America
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The Pace of Change in Surface Finishing
• Typically, it doesn’t happen quickly,
• More often, it can be measured in years….
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Accelerating Change
Each industrial sector is pressured by many of the
same factors, but the rate at which they adopt the
change varies.
Some familiar factors that can initiate change...
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REGULATIONS
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REGULATIONS
SPECIFICATIONS
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REGULATIONS
SPECIFICATIONS
NEW
TECHNOLOGY
COST REDUCTION
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Technology Tradeoff /
Increase in Health &
Safety Costs
Imp
lemen
tation
REGULATION – Often initiates the change ahead of
market driven innovation
Material/Fo
rmu
la
Co
ntro
l
Hazard
/Disp
osal
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Regulations Take Flight
DoD Directives for Complying with Environmental Restrictions on Cadmium & Hex Chrome
• Cadmium solutions contain cyanide and cadmium salts.
• EPA – Targeted for reduction under Industrial Toxics & Chemicals of Concern (COC)
• OSHA – Worker (PEL) limits.
• RCRA – Disposal of Hazard Materials from plating and wash down.
• REACH
Phasing out the Exemptions and Waivers
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What Took So Long? Aerospace is a very risk averse industry
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Cadmium & Hexavalent Chromate:
• relatively inexpensive & simple to operate, very good
corrosion resistance, adhesion to high strength steel, low
hydrogen embrittlement...etc..
• No single alternative was necessarily going to check all of the
right boxes.
In use for decades – all the infrastructure and knowledge was
embedded for supporting and maintaining this process
application, very much a tried and true process.
If It’s Not Broke....
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Several Finishes Were Investigated For Landing Gear Applications
However, none were just right.
• Zinc – voluminous corrosion products.
• Sn-Zn – lower temperature resistance.
• Ti-Cd – still toxic.
• Early low nickel Zn-Ni formulas –
hydrogen embrittlement issues.
Some Examples:
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Some Were Qualified
IVD – Line of sight only for O.D.
areas. Expensive to maintain.
Aluminum Sputtering –
Complex & Expensive to
operate.
Aluminum Plating – very limited
supplier base.
But still had limitations...
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A Timeline of Investigation & Testing
1996-2000
Boeing developed
Acid ZnNi
Alkaline ZnNi –
Low Ni (5-8%)
2003-2005
LHE Alkaline ZnNi
– High Ni (12-15%)
2006-2007
Prototype
Installation,
Qualification
Testing
2007-2009 2009-2013
Additional
Prototype
Installations, &
Continued
Qualification
Testing
Process Qualified,
Large Scale Plating
Installations
2013 Continued Conversion
away from Cadmium.
Assessing Cobalt Free
Passivates
Phase I, II, III... Testing Verifications
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The Journey – Some of the Qualification Requirements For LHE ZnNi Over High Strength
Steel 1. Adhesion (ASTM B571)
2. Corrosion (ASTM B117)
3. Fatigue (ASTM E466)
4. Hydrogen Embrittlement (ASTM F519 & USAF DWG)
5. Liquid and Solid Metal Embrittlement (ASTM F519)
6. Brush Plating for Repair of Damage (ASTM B117, B571 and F519)
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Adhesion Testing
Impact at 70 in-lbs
Impact Testing
The following two slides
demonstrate that SEM
analysis shows no loss
of adhesion with the Zn-
Ni plated high strength
steel coupons.
Performance matched
that of cadmium.
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Adhesion : Impact Testing of Zn-Ni
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Adhesion: Impact Testing of Cadmium
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Adhesion Testing
• Adhesion of the LHE Zn-Ni coating to the substrate was tested per ASTM B571
• All adhesion test coupons were manufactured from 1”x 4”x 0.040” 4130 steel sheet
• Results: All Test coupons passed
Overall Conclusions: Zn-Ni has adhesion as good as Cadmium when tested by bend-to-break and impact test methods and passes ASTM B571
Bend to Break Tests On LHE Zn-Ni Test Coupons
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Corrosion Performance • Corrosion tests were conducted on LHE Zn-Ni coupons
with Cadmium as the baseline
• Testing was also performed on both cadmium and LHE Zn-Ni coated coupons with a prime/paint topcoat after being scribed (See Table below). All test coupons were 4”x 6”x 0.040” 4130 steel sheet
• All testing was performed per ASTM B117
• Test specimens were both scribed and un-scribed
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Test per ASTM B 117
Corrosion Performance – LHE ZnNi
1000 hours
3000 hours
5000 hours
IZ-C
17+
Zn
-Ni w
ith T
rivale
nt C
hro
me C
onve
rsio
n C
oating
Unscribed
–A
ST
M B
117
Fig
ure
4
1000 hours
3000 hours
5000 hours
IZ-C
17+
Zn
-Ni w
ith T
rivale
nt C
hro
me C
onve
rsio
n C
oating
Scribed –
AS
TM
B 1
17
Fig
ure
6
Un-scribed Scribed
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Tested per ASTM B 117
Corrosion Performance - Cadmium C
ad
miu
m w
ith
He
xa
va
len
tC
hro
me
Con
ve
rsio
n C
oatin
g
Unscrib
ed
–A
ST
M B
117
Fig
ure
3
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
1000 hours
3000 hours
5000 hours
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
1000 hours
3000 hours
5000 hours
Cad
miu
m w
ith
He
xa
va
len
tC
hro
me
Con
ve
rsio
n C
oatin
g
Scribe
d –
AS
TM
B 1
17
Fig
ure
5
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Test Panel
Removed From
Salt Spray Cabinet –
Excess Amount
of Red Rust
Detected
Un-scribed Scribed
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Corrosion Result: (Paint & Scribe)
LHE Cd w/Hex CC
Tested per ASTM B117
LHE Zn-Ni w/Tri CC
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Corrosion Results
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Corrosion Results
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Corrosion – Testing Summary
• Plated and Scribed / Un-scribed (ASTM B-117)
• Cadmium with hex chromate: Failure at 1000 hours
• LHE ZnNi with Tri CC: Passed at 1000 hours
• Acceptable results at 5000 hours
• Plated + Paint and then Scribed (ASTM B-117) • Cadmium/Hex CC + primer + paint then Scribed: Pass at 1000 hours
• LHE ZnNi/Tri CC + primer + paint then Scribed: Pass at 1000 hours
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Fatigue Testing
Load-controlled axial fatigue testing was performed to evaluate any service life impacts associated with LHE Zinc-Nickel.
Plated Test Bars Test Cell
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Fatigue Validation
Test Conclusions:
LHE Zinc-Nickel was comparable to Cadmium.
200 KSI
180 KSI
160 KSI
30,000
100,000
1,000,000
# o
f Cycle
s
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Hydrogen Embrittlement Testing
• V-notch test samples manufactured per ASTM F519 specifications (4340)
• Additional test samples plated and tested at additional dates
• All v-notch samples tested per ASTM F519 passed the 200 hour sustained load tests @ 75% of the tensile notch fracture strength
ASTM F519 Type 1A.1 Test Samples
Testing Equipment
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New fixture and Conformal Anode Design
Additional Hydrogen Embrittlement Testing
Original Chain Design
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Re-Embrittlement Testing Results
Additional, 3.5% salt water, re-embrittlement testing was conducted on LHE Zn-Ni plated coupons and they all passed the ASTM 519-06 150 hour requirement
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Liquid/Solid Embrittlement Testing
• Liquid and Solid Metal Embrittlement (LME and SME) occur when one metal, either as a liquid or solid, intrudes into the structure of another, potentially causing embrittlement in the base metal
• Melting points for the coating metals are as follows:
• Cadmium ~610°F
• Zinc ~787°F
• Nickel ~2650°F
Liquid Metal Embrittlement Test #3
300M Type 1a.1 Plated with Zn-Ni (Lt.) and Cd (Rt.)
After Being Step Loaded to Failure
Cadmium = 91.5% NFS : Zinc-Nickel = 100% NFS
Fracture Surface of Zn-Ni and Cd After Step Load to
Failure – Cadmium Had Pre-Existing Crack from High
Temp Exposure Under Stress
LHE Zn-Ni and Cad Type 1a.1 Specimens After ISL Test to Determine the NFS After Exposure to 400oF for 200 Hours
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Brush Plating Repair • In order for a brush LHE Zn-Ni plating to qualify it
must pass the following tests:
• Hydrogen Embrittlement (HE) testing per ASTM F519
• Bend to break adhesion test per ASTM B571
• Corrosion testing per ASTM B117
• SIFCO recommended procedures to use for plating several sets of HE type 1a.1 coupons, adhesion coupons, and corrosion coupons, using SIFCO 4018 No Bake LHE Zn-Ni brush plating solution
• Brush Plating Repair performed as well as original plated finish.
Test Results Summary
• Passed hydrogen embrittlement testing
• Passed adhesion testing on steel and LHE Zn-Ni plated steel
• Corrosion test performance is excellent
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Next Steps: Prototype Implementation
• Customer implemented a tank of approximately 325 gallons for the purpose of demonstrating the LHE Zn-Ni plating process on full sized gear components
• The demonstration tank was used to develop uniform plating thicknesses and process parameters on test coupons and full scale landing gear components
• During the plating operations Quality Assurance testing has been conducted to ensure the alkaline LHE Zn-Ni solution is within proper process limits
LHE Zn-Ni Plating Tank
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LHE Zn-Ni Performance Tracking Program (PTP)
• Criteria for part selection • Fixture Completed
• 2 to 3 Parts from each Weapon System
(NLG & MLG)
• Ease of access to component on aircraft
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C-130 Main Landing Gear Components
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Landing Gear Components
F-15 Platform F-16 Platform
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MLG Axle plating in LHE Zn-Ni Solution
Before Plating After Plating
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MLG Outer Cylinder
LHE Zn-Ni Conformal Anode and
Fixture Models
Complex Geometries
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Field Corrosion
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Component Corrosion Evaluation LHE Zn-Ni Plating (Cape Kennedy)
F-15 MLG Lower Drag Brace CAD F-15 MLG Lower Drag Brace Zn-Ni
Parts Placed 10/13/2010, Pictures taken 7/24/2012
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Component Corrosion Evaluation LHE Zn-Ni Plating (Cape Kennedy)
C-5 MLG Rotation Collar Zn-Ni C-5 MLG Rotation Collar CAD
Parts Placed 10/13/2010, Pictures taken 7/24/2012
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Reaching the Goal 1. Adhesion (ASTM B571) – Passed
2. Corrosion (ASTM B117) - Passed
3. Fatigue (ASTM E466) - Passed
4. Hydrogen Embrittlement (ASTM F519 & USAF DWG) - Passed
5. Liquid and Solid Metal Embrittlement (ASTM F519) - Passed
6. Brush Plating for Repair of Damage (ASTM B117, B571 and F519) - Passed
• Qualified:
• Boeing BAC 5680 & Boeing BAC 5637
• USAF Drawing# 201027456
• UTC Aerospace Systems LGPS 1106 Landing System
• Heroux-Devtex HPS-138
• SAE AMS 2417
• Bell Helicopter #5445
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A Change for the Better
• LHE Zn-Ni and trivalent passivate most closely matched and in many cases surpassed the performance requirements of cadmium and hexavalent chromate.
• Provided a process that was more of a “drop-in” replacement compared to other technologies.
• Legacy knowledge and infrastructure was more readily transitioned over to LHE Zn-Ni + trivalent passivate.
• Zinc-Nickel plating continues to be a viable option for existing and new applications that require replacement finishes to meet regulatory or increased performance requirements.
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Or Is It?
Successful Change, So...
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Nickel? Chrome
Free Cobalt Free
From Hexavalent to
Trivalent Passivates
Staying Relevant
AUTOMOTIVE
Our Industry Continues to Innovate
From Cyanide to
Alkaline Non-Cyanide
Plating
• Regulations will continue to push changes in our industry.
• Timeframes narrow as replacement substances then become future candidates for restriction.
• Competent & willing partners may be needed to share in the costs of developing these alternative technologies.
AEROSPACE
ELV
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“When you’re finished changing, you’re finished.”
- Benjamin Franklin
Thank you
Questions or Comments
Dipsol of America